Octagon shaped tray and corresponding blank

ABSTRACT

The present invention includes and blank and container formed from cellulose based material configured to form an octagon shaped tray. The tray includes a roll-over side wall that provides structural rigidity as well as simple and fast container set-up. The octagon shape provides a relatively strong tray for the storage of products within. The tray may have solid walls, a single first side panel flap, or a pair of opposed first side panel flaps. The side panel flaps allow a user to see or access the contents of the tray as well as providing ventilation. Corner gussets provide additional structural integrity.

FIELD OF THE INVENTION

This invention relates generally to blanks and their resultingcontainers, and more specifically to the blanks and containers formingoctagonal-shaped trays with rolled side panels.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present invention are described in detailbelow with reference to the following drawings.

FIG. 1 is a plan view of a single piece container blank formed inaccordance with the present invention;

FIG. 2 is a perspective view of a partially assembled containeraccording to the present invention;

FIG. 3 is another perspective view of a partially assembled containeraccording to the present invention;

FIG. 4 is yet another perspective view of yet another partiallyassembled container according to an aspect of the invention;

FIG. 5 is yet another perspective view of a partially assembledcontainer made in accordance with the present invention; and

FIG. 6 is a perspective view of an assembled container according tovarious aspects of the present invention depicted in FIG. 1.

DETAILED DESCRIPTION

The present invention will now be described with reference to theaccompanying drawings. The present invention is directed to a blank 20and a container 50 that utilizes an octagonal shape to impart strengthand stability. One suitable embodiment of the blank 20 and container 50constructed in accordance with aspects of the present invention isillustrated in FIGS. 1 through 6. Specific details of the blank 20 andthe resulting container 50 are described in more particularity below.

FIG. 1 depicts a blank 20 used to form the container 50. The blank 20 istypically constructed from a single piece of formable material such as,without limitation, sheets of cellulose-based materials formed fromcellulose materials such as wood pulp, straw, cotton, bagasse or thelike. Cellulose-based materials used in the present invention come inmany forms, such as fiberboard, containerboard, corrugatedcontainerboard and paperboard. The blank 20 is cut and scored,perforated or otherwise formed into a plurality of panels that whenassembled form container 50. In all FIGURES, like numbers indicate likeparts. Additionally, cut lines are shown as solid lines, score lines asdashed lines, and lines of perforation as broken lines. For the purposesof further description herein, the downward direction is defined as thedirection perpendicular to the first bottom panel 30 that corresponds tothe outer surface of the first bottom panel 30 when the container 50 hasbeen erected. The upward direction is defined as the directionperpendicular to the first bottom panel 30 that corresponds to the innersurface of the bottom panel when the container 50 has been erected.

Referring now to FIG. 1, the blank 20 includes a first side panel 22.Attached to the first side panel 22 along a fold line 23 is a secondbottom panel 30. The second bottom panel 30 is substantially trapezoidalin shape and has a length measured in a direction parallel to a foldline 23 that is greater than the length of the first side panel 22measured along the same fold line. The first side panel 22 is alsoattached with a first angled corner panel 26 along a fold line 21. Theplurality of first angled corner panels 26 are substantially rectangularin shape.

Attached to the first angled corner panel 26, opposite the first sidepanel 22, is a second side panel 24. The second side panel 24 issubstantially rectangular in shape. The second side panel 24 is alsoattached with another first angled corner panel 26 opposite the firstangled corner panel 26 that lies between the first side panel 22 and thesecond side panel 24. The second side panel 24 is also attached with afirst bottom panel 28 along a fold line 37. The first bottom panel 28 issubstantially rectangular in shape. Disposed through the first bottompanel 28 are slot(s) 44.

Attached to the second side panel 24, opposite the first bottom panel28, are a pair of spaced-apart fold lines indicated by fold lines 31.These spaced-apart fold lines 31 form a rolled corner panel 36 therebetween. Attached with the rolled corner panel 36 opposite the secondside panel 24 is a second side panel flap 38. The second side panel flap38 has substantially the same geometry and size as the second side panel24. On an edge opposite the rolled corner panel 36, the second sidepanel flap 38 has at least one locking tab 42 extending there from. Theposition and size of the locking tab 42 is configured to match theposition and size of the slot 44 in the first bottom panel 28.

Disposed upon opposing ends of the second side panel flap 38 are secondangled corner panels 40. The second angled corner panels 40 areconnected with the second side panel flap 38 along fold lines 33. Thesecond angled corner panels 40 are substantially rectangular in shapeand sized similarly to the first angled corner panels 26.

One of the features of the present invention shall now be discussed.Specifically, the first side panels 22 may or may not include a firstside panel flap 34 formed within the first side panel 22. As depicted inthe FIGURES, only one of the first side panels 22 includes the firstside panel flap 34. However, it will be understood that none of thefirst side panels 22 may include the first side panel flap 34 (notshown). Alternatively, both first side panels may include first sidepanel flaps 34 (not shown).

FIGS. 2-6 depict various stages of the container 50 being erected fromthe blank 20. Specifically, the various first side panels 22, secondside panels 24, first bottom panels 28, second bottom panels 30, andfirst angled side panels 26 are folded over one another such that thetwo, singularly attached, first angled side panels 26 lay juxtaposed oneanother. At this time the first angled corner panels 26 that arejuxtaposed to one another may be fastened together. Suitable nonlimitedexamples of methods of fastening the respective first angled cornerpanels 26 include mechanical and chemical binders. Suitable, nonlimitingexamples of chemical binders include adhesives, glues, or tapes.Alternatively, suitable, nonlimiting examples of mechanical bindersincludes staples, brads and tacks. As best seen in FIG. 3, the panels,attached only at the respective first angled corner panels 26, may bepushed relative to one another to form the general outline the erectcontainer 50.

With specific reference to FIGS. 4 and 5, the continued formation of thecontainer 50 is shown. Specifically, the first bottom panels 28 may befolded inwardly approximately 90 degrees along fold lines 37. Likewise,the second bottom panels 30 may be folded inwardly approximately 90degrees along a fold line 21. The status of the container formation withrespect to this stage of formation is best depicted in FIG. 4. As can beseen, the bottom is substantially sealed off with the respective firstbottom panels 28 and second bottom panels 30. Also the footprint of thecontainer 50 is substantially formed at this stage.

With specific reference to FIG. 5, the final formation of the container50 is depicted. Specifically, the second side panel flap 38 may befolded inwardly approximately 180 degrees along the two spaced-apartfold lines 31. In this fashion, the rolled corner panel 36 lies in asubstantially horizontal orientation along the top end of the container50. Upon folding the second side panel flap 38 inwardly approximately180 degrees, the locking tabs 42 may be inserted into the slots 44 inthe second side panels 28. This will substantially lock the container inplace. It will be noted that by folding the second side panel flap insuch a manner that the second angled corner panels 40 now liesubstantially traverse the corners of the container 50, forming asubstantially triangular shaped corner defined by the second angledcorner panels 40, the first angled corner panels 26 and that portion ofthe rolled corner panel 36.

At this point, depending upon the box design, this box is substantiallyformed. However, where the container 50 includes a first side panel flap34, the container 50 is not quite formed. Specifically, the first sidepanel flaps 34 may be folded downward inwardly approximately 180 degreesalong a fold line 43. The locking tabs 42 that are located on theoutermost edge of the first side panel flap 34 may then be inserted intorespective slots 44 in the second bottom panel 30. It will beappreciated that, as discussed earlier, the first side panels 22 may notinclude a first side panel flaps 34 (not shown). Alternatively, bothfirst side panels 22 may include a first side panel flap 34. It will beappreciated that any necessary respective tabs 42 and slots 44associated with the presence or absence of the first side panel flap(s)34 will be included or omitted as necessary without departing from thespirit and scope of this invention.

FIG. 6 depicts the formed container 50. It will be appreciated that thecut-outs formed by the first side panel flap 34 allow for ventilation aswell as viewing the product contained therein. Likewise the rolledcorners on the end of the panels on the second side panels 24 providestability to the container 50 and a self-locking feature for lockingtabs 42 into slots 44. Finally, the gusseted corners created by thefirst angled side panels 26 and the second angled side panels 40 providefor lateral stability as well as increase the overall stacking strengthof the container 50.

While various embodiments of the invention have been illustrated anddescribed, as noted above, many changes can be made without departingfrom the spirit and scope of the invention. Accordingly, the scope ofthe invention is not limited by the disclosure of the variousembodiments; instead the invention should be determined entirely byreference to the claims that follow.

1. A single sheet of foldable material cut and scored to define acontainer blank, comprising: a first side panel; a first angled cornerpanel connected with said first side panel; a second side panelconnected with the first angled corner panel, opposite the first sidepanel; a second side panel flap connected with said second side panel bya pair of spaced apart fold lines; and, a second angled corner panelconnected with said second side panel flap; wherein said first angledcorner panel is substantially the same size and shape as the secondangled corner panel.
 2. The container of claim 1, wherein the singlesheet of foldable material is formed from a cellulose-based material. 3.The container of claim 2, wherein the cellulose based material is formedfrom at least one of a wood pulp, straw, cotton, and bagasse.
 4. Thecontainer of claim 2, wherein the cellulose based material is in theform of at least one of a fiberboard, containerboard, corrugatedcontainerboard and paperboard.
 5. The container of claim 1, furthercomprising a first bottom panel connected with the first side panel. 6.A single sheet of foldable material cut and scored to define acontainer, comprising: a first side panel; a first angled corner panelconnected with said first side panel; a second side panel connected withthe first angled corner panel, opposite the first side panel; a secondside panel flap adjacent the second side panel; a second angled cornerpanel extending between the second side panel flap and the first sidepanel, wherein the second angled corner panel and the first angledcorner panel lie in intersecting planes.